Panel attachment system

ABSTRACT

A panel attachment system for mounting panels to construct a wall structure generally utilizes interconnecting panel assemblies comprising panels with frames attached thereto. Each frame includes a generally outwardly facing channel disposed proximate the perimeter of the panel for receiving a spline member used to interconnect adjacent panel assemblies. Preferably, the spline members secure adjacent panel assemblies together and seal abutting edges of the adjacent pieces of the resulting wall structure. Connection members, such as molding pieces, including at least one generally outwardly facing channel for receiving a spline member can be used to connect adjacent panel assemblies or to finish an edge of a panel assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/796,832, filed May 1, 2006, and Canadian Application No. 2,573,008,filed Jan. 5, 2007, both of which are entitled “PANEL ATTACHMENTSYSTEM”. Applicant claims priority of both of the above-identifiedapplications which are incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to a panel attachment system formounting panels to construct a wall structure or the like, and morespecifically relates to a panel attachment system using a series ofinterconnecting panel assemblies mountable to a building structure toconstruct a wall structure or the like.

BACKGROUND OF THE INVENTION

Many systems for constructing walls in both the interior and exterior ofbuildings exist in prior art. Most such systems involve lengthy andlaborious, occasionally multi-step, processes and achieve varyingdegrees of results. For instance, a common multi-step process calls forwall panels to be screwed to the building exterior. The seams and screwheads are then covered with a cement product, the corners reinforcedwith mesh and similarly covered, and the entire surface is coated withthe desired finishing material. Later, thermal expansion joints must becut and filled with a resilient architectural-grade caulk to protectagainst structural damage due to the effects of thermal expansion andcontraction on the wall panels. Such a process is costly and requiresworkers to make a minimum of three separate trips to the building siteto complete installation of a finished wall. A further drawback of sucha multi-step process is that the finishing step must be performed whentemperatures will remain above freezing due to the threat of surfacecracking from thermal expansion and contraction, and therefore limitsthe construction timeline, especially in colder climates.

A similar method for constructing walls and particularly interior wallsincludes building a wall frame using vertically disposed wooden,metallic or polymeric composite frame pieces or studs, and then securingpanels of wall-lining material, such as wallboard, to the wall frame.The panels are often secured to the wall frame using common fasteners,such as wallboard screws or nails. To ensure a flat and smooth wall, thefasteners are liberally applied—often screws are used to attach eachpanel at multiple places about the area of the panel corresponding toeach stud positioned behind the panel. The seams and screw heads need tobe covered with a cement or plaster product, and the corners need to bereinforced with mesh and similarly covered. The entire surface of thewall may be coated with a desired finishing material. Again, such aprocess takes multiple steps to achieve a finished wall, and accordinglyis time consuming and costly.

Existing panel mounting systems involving the attachment of panels to apre-built frame structure use alternate means for mounting the panels tothe wall frame. For example, U.S. Pat. No. 6,951,087 discloses a framestructure comprising vertical C-profiles mounted with respect tosimilarly shaped horizontal C-profiles to form a grid-like wall framestructure. Bracket clips are then attached to the vertical C-profiles atequivalent heights and form the support for horizontally positionedZ-rails. The wall is then formed by attaching panels directly to thegrid frame by fastening them to the Z-rails. However, such a systemmerely provides a means to mount panels to the pre-built framestructure, and does not obviate the need to seal the seams and screwholes after the panels have been mounted.

Other inventions exist that disclose systems for attaching adjacentpanels in a wall structure to each other using clips or similar devicesto secure their connection and the stability of the entire wall. Forinstance, U.S. Pat. No. 3,837,133 discloses a clip device employed tohold adjacent panels together to enable such panels to be attached tonearby wall studs. Again, such devices focus on mounting the panels to awall frame, but do not eliminate the need to seal and finish the wallafter the panels have been mounted.

Accordingly, a need exists for a panel attachment system that not onlyprovides for easy and secure attachment of wall panels to a wallstructure or frame, but that also reduces and even eliminates the costlyand time consuming steps associated with positioning and connectingadjacent panels, and then sealing and finishing the panels aftermounting. The present invention eliminates the drawbacks of prior artwall paneling systems while reducing the time of construction. Thepresent invention has the advantages of allowing the erection of fullyfunctional, weatherproofed walls in one pass without the need to furthertreat the wall structure, thus eliminating shortcomings of previouslydisclosed systems.

SUMMARY OF THE INVENTION

The present invention provides a panel attachment system forconstructing a wall structure that comprises at least one panel assemblyand at least one spline member to interconnect the panel assembly to anadjacent portion of the wall structure. The panel assembly comprises apanel having a perimeter, a front face and a rear face, and a frameattached to the rear face of the panel and including a generallyoutwardly facing channel disposed proximate the perimeter of the panel.The spline member is insertable into the channel of the frame tointerconnect the corresponding panel assembly to an adjacent portion ofthe wall structure, such as another panel assembly or a molding element.

In an embodiment of the present invention, the panel attachment systemcomprises a plurality of panel assemblies, wherein each panel assemblycomprises a panel having a perimeter, a front face and a rear face, anda frame attached to the rear face of the panel and including a generallyoutwardly facing channel disposed proximate the perimeter of the panel.The channels along abutting edges of adjacent panel assemblies face oneanother such that the adjacent panel assemblies are interconnected via aspline member placed within respective facing channels.

Preferably, the panels have a rectangular perimeter, but panels for usewith the present invention may be constructed of various shapes anddimensions in accordance with the design of the wall that the panels arebeing used to construct. In preferred embodiments, the frame has aperimeter shape that corresponds to the perimeter shape of the panel towhich it is attached, and the channels in the frames are disposedproximate the edges of the panels.

In an alternate embodiment, the present invention is directed to a framestructure for attachment to pre-fabricated wall panels to form panelassemblies that can be interconnected using spline members insertableinto channels defined in frame members that form the frame.

In an alternate embodiment of the present invention, connection members,such as molding pieces, including at least one generally outwardlyfacing channel for receiving a spline member can be used to connectadjacent panel assemblies or to finish an edge of a panel assembly.

In constructing a wall using the panel attachment system of the presentinvention, a first panel assembly is mounted to a wall frame structure.A spline member is inserted into a channel in the frame of the firstpanel assembly. A second panel assembly, or alternatively, a connectionmember or a molding piece is mounted to the wall frame structure withthe spline member being inserted into a channel adjacent to and facingthe first panel assembly. Additional panel assemblies or connectionmembers/molding pieces may be added and interconnected using additionalspline members to secure and seal abutting edges of the adjacent piecesof the wall structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a panel attachment system in accordancewith the present invention.

FIG. 2 shows a schematic view of the rear face of a panel assembly usedin the panel attachment system.

FIG. 3 shows a side profile of an embodiment of the panel assembly ofFIG. 2.

FIG. 4 shows an embodiment of a section of a frame track including agenerally U-shaped channel for use with a panel assembly of the presentinvention.

FIGS. 5A-5E show several embodiments of spline members used to attachadjacent components of a panel attachment system of the presentinvention.

FIGS. 6A-6D show several embodiments of molding components for use witha panel attachment system of the present invention.

FIGS. 7A-7C show a series of partial side views of the interconnectionof adjacent molding components.

FIGS. 8A and 8B show respective schematics of the front face and therear face of the panel attachment system of the present inventioninstalled to create a wall structure showing the interconnection ofseveral panel assemblies.

FIGS. 9A and 9B show enlarged views of the areas A and B of the panelattachment system of FIGS. 8A and 8B, respectively, with the splinemember shown in hidden lines.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, a panel attachment system for constructing a wallstructure in accordance with the present invention is shown generally asreference number 10. The system generally comprises a plurality of panelassemblies that may be interconnected to form the wall structure. Asillustrated in FIG. 1, a first panel assembly 12 a is interconnectedwith an adjacent second panel assembly 12 b via a spline member 14. Amolding piece 16 can be interconnected at the edges of the panelassemblies 12 a and 12 b using a spline member 14. The molding piece 16could also be designed as a connection member to be positioned betweenpanel assemblies and interconnected thereto with spline members.

Preferably, the general structure of panel assemblies in the system 10(as described herein) is identical. However, the size, shape andappearance of the panel assemblies can vary depending on the shape anddesign of the wall and/or room, as well as other variables, such as thepresence of a window or door in the wall. In preferred embodiments ofthe panel attachment system 10, adjacent panel assemblies 12 a and 12 bare interconnected so that the respectively adjacent edges of panelsmounted thereon essentially abut one another. The interconnecting splinemember 14 provides an adequate, preferably weatherproof, seal for thejoint or seam between the panel assemblies 12 a and 12 b and eliminatesthe need to seal or otherwise finish the panels after interconnection.The presence of the spline member 14 between adjacent panel assemblies12 a and 12 b also means that the abutting edges of the panels need notbe flush, and certain design features, such as grooves or spaces betweenpanels may be incorporated into the wall design without sacrificing theseal between the panels. Though additional finishing steps may be taken,such as painting the panels or adding decorative grout between abuttingpanel edges, a finished wall structure can be constructed using thepresent invention in a single construction step involving mountingpre-painted panel assemblies to a wall frame and interconnecting themusing spline members 14. Such a single step process is especially usefulfor constructing exterior walls of building structures where the wallpanels often comprise pre-finished concrete, marble, stone, or compositepanels. The specific assembly of the components of the panel attachmentsystem 10 using spline members 14 to construct a wall structure isdiscussed in more detail below.

As shown in FIG. 1, panel assemblies 12 a and 12 b have like structure.Accordingly, discussion of the preferred components of a panel assemblyof the present invention is provided with respect to a generic panelassembly 12 illustrated in FIG. 2.

Each panel assembly 12 of a preferred panel attachment system 10comprises a panel 18 and a frame 20. Each panel 18 has a front face 22,a rear face 24 and a perimeter 26 that generally defines the outer edgesof the panel 18. Panels for use with the panel attachment system 10 canbe made of any common panel material for either interior or exteriorapplication to construct a wall structure, including wallboard, wood,plaster board, concrete, marble, stone-work, composite material, or thelike.

The frame 20 comprises at least one track member 28 that defines achannel 30. In a preferred embodiment, the channel 30 has a generallyU-shaped cross section, but may have any form provided it sufficientlyinteracts with the spline member 14 as described herein. The trackmember 28 is attached to the rear face 24 of the panel 18 so that thegenerally U-shaped channel 30 is positioned proximate the perimeter 26of the panel 18 to which the frame 20 is attached and so that thegenerally U-shaped channel 30 faces outward from the frame 20 toward theedges of the panel 18. The frame 20 is preferably made of a rigidmaterial that provides the panel assembly 12 with adequate stability.For example, the track members 28 can be manufactured from high-gaugegalvanized steel or a similar material that will stabilize the wallpanel 18 attached thereto. An additional stabilizing track 32 can beadded to the frame 20 to increase the rigidity thereof. Additionalrigidity is useful for increasing the effectiveness of mounting largepanels, and especially heavy panels, such as those typically used forexterior wall applications. In the embodiment illustrated in FIG. 2, thestabilizing track 32 is vertically positioned through the center of theframe 20, and attached, commonly by welding, at a position approximatelyequidistant from the side edges the frame 20. Alternatively, thestabilizing track 32 can be horizontally or diagonally disposed, ormultiple stabilizing tracks can be used in a variety of vertical,horizontal or diagonal positions, or a combination thereof, depending onthe design of the frame 20. As illustrated, the stabilizing track 32 hasthe U-shaped channel design as used along the perimeter of the frame 20.However, the stabilizing track 32 does not require the U-shaped channeland can be any design sufficient to stabilize and add desired rigidityto the frame 20.

In a preferred design of the panel assembly 12, the perimeter 26 of thepanel 18 defines a rectangular shape with four edges in accordance withcommon supplies of wall panels available on the market. The frame 20preferably has a corresponding rectangular perimeter shape and agenerally outwardly facing channel 30 defined along each side of theframe perimeter such that the channels 30 are disposed proximate each ofthe edges of the panel 18. As shown in FIG. 2, the frame 20 comprisesfour track members 28, each defining a generally U-shaped channel 30.The track members 28 can be connected to form the frame 20 by any knownmeans, such as welding. Though the general shape of the panel 18 and thecorresponding frame 20 is rectangular, panel assemblies 12 in accordancewith the present invention can be constructed of any size, shape ordimension, especially if the specific design of the wall structure to beconstrued requires panels of specific size, shape or dimension. Theedges of the panel 18 also need not be straight, and could incorporateany desired design elements, including curved, waved or serrated edges,provided the edge of the adjacent panel has a substantiallycomplementary shape to facilitate construction of the wall. Even insituations where the size, shape or dimension of the panels or thedesign of the edges of the panel vary, the generally outwardly facingU-shaped channels 30 defined in the frame 20 should be disposedproximate the edges of the perimeter 26 of the panel 18 so as tofacilitate interconnection of adjacent panel assemblies 12 using splinemembers 14. Indeed, where the edges of adjacent panels 18 are notstraight, the respective frames 20 should be designed and arranged sothat complementary U-shaped channels 30 along the abutting edges ofadjacent panel assemblies 12 are straight to facilitate interconnectionvia spline member 14.

The frame 20 preferably includes fastening members 34 for attaching theframe 20 to the rear face 24 of the panel 18. As illustrated in FIG. 4,the fastening member 34 can take the form of a flange 36 having a hole38 therein through which common fasteners, such as screws, bolts ornails, may be inserted to attach the frame 20 to the panel 18. Alternatemeans for fastening the frame 20 to the panel 18 known to those skilledin the art, such as adhesives, hooks, or interconnecting membersrespectively positioned on the panel 18 and the frame 20, can be used.In order to improve the connection between the panel 18 and the frame20, fastening members 34 can also be provided on the stabilizing track32 so as to ensure that the center of the panel 18 does not warp orbubble after the wall is constructed.

The frame 20 may also include mounting members 40 for mounting the frame20 to a pre-built wall frame structure. As illustrated in FIG. 4, themounting member 40 can take the form of a hook 42 having a hole 44therein through which common fasteners, such as screws, bolts or nails,may be inserted to attached the panel assembly 12 to a wall framestructure. Though illustrated in the form of hooks 42, the mountingmembers 40 can comprise any structure that enables attachment of thepanel assembly to a building structure. Moreover, though the mountingmembers 40 are shown attached to the frame 20, the present inventionalso covers a panel assembly 12 wherein the mounting members 40 areattached to the rear face 24 of the panel 18.

Referring to FIG. 3, a side profile of the panel assembly 12 mounted toa wall frame structure 46 of a building is shown. The wall framestructure 46 commonly comprises a plurality of vertical studs on which aplurality of horizontal Z-bars 48, or cross members, is disposed to forma grid-like frame structure. A Z-bar is a known form of cross-memberused in the art of wall construction for mounting wall panels.Typically, the Z-bar 48 has a Z-shaped cross-section and is made fromgalvanized sheet metal, or a metallic material of similar strength. Whensuch a wall frame 46 is used to construct a wall structure, the innerportion of the Z-bar 48 is attached to the vertical studs. The outerportion of the Z-bar 48 extends away from the studs to engage the wallpanels. Z-bars 48 are commonly positioned every two feet. In accordancewith the present invention, the mounting members 40 are positioned onthe frame 20 so that they catch the outer portion of the Z-bars 48 fromabove. Thus, hooks 42 may be positioned every vertical two feet on theframe 20, including on the stabilizing track 32 where desirable. Afterthe panel assembly 12 is properly positioned on the horizontal Z-bars48, selected hooks 42 may be fastened to the Z-bar 48 by common means,such as screws, through the hole 44 in the side of the hook 42 facingaway from the panel 18, as seen more clearly in FIG. 4. Since thepresent invention allows for mounting and attachment of the panelassemblies 12 without screwing into or through the front face 22 of thepanel 18, unlike in prior art wall construction methods and systems,there is no need to fill or conceal the screw holes after the panelassembly 12 is mounted to the wall frame 46. As FIG. 3 furtherillustrates, the present panel attachment system 10 provides for spacebehind each panel 18 permitting ventilation within the wall structureand therefore reducing the probability and risk of problems caused byenvironmental factors, such as temperature fluctuations or highhumidity.

As FIG. 2 illustrates, the mounting members 40 may be positioned alongtrack members 28 of the frame 20 in an offset manner. The offsetpositioning of mounting members 40 allows adjacent edges of panelassemblies to abut against adjacent edges of other panel assemblies inthe wall structure, therefore eliminating the requirement of furtherweatherproofing, sealing or finishing steps after construction of thewall structure.

FIG. 4 provides a close-up view of a track member 28 used to constructthe frame 20 of the present invention. The track member 24 has an innersurface 50 defining the channel 30 and an outer surface 52 to whichfastening members 34 and mounting members 40 are attached, for example,by welding. As shown, the fastening member 34 includes the flange 36 andthrough hole 38, and is attached to the track member 28 on a side of theouter surface 52 that will contact the rear face 24 of the panel 18 towhich the track member 28 will be attached. The mounting member 40,including hook 42, is attached to the track member 28 on a side of theouter surface 52 that will face away from the panel 18 to which thetrack member 28 will be attached. Preferably, hook 42 includes thethrough hole 44 in the side away from the panel 18 through which thehook 42 can be screwed to a Z-bar 48 after the frame 20 is properlymounted, as shown in FIG. 3. Other fastening means can be employed inaccordance with the knowledge of one skilled in the art. In a preferredembodiment of the panel assembly 12, the particular track member 28illustrated in FIG. 4 would be positioned generally horizontallyproximate the lower edge of the perimeter of the rear face 24 of thepanel 18.

As shown in FIG. 1, the spline member 14 is used to interconnectadjacent panel assemblies 12 a and 12 b, as well as to connect a moldingpiece 16 to panel assemblies 12 a and 12 b. FIGS. 5A-5E illustratevarious designs of spline members, designated by reference numbers 14 ato 14 e, respectively, that can be used to interconnect and seal variousportions of the wall structure. FIG. 5A illustrates the basic flatdesign of the spline member 14 a used in FIG. 1. Such a spline member 14a is typically used to connect flat portions of a wall structure thatare positioned adjacent one another, such as panel assemblies as shownin FIGS. 1, 9A and 9B. In such an embodiment, relatively half of thewidth of spline member 14 a is inserted lengthwise along preferably theentire length of an outwardly facing U-shaped channel of a first panelassembly (such as assembly 12 a), then the remaining half width ofspline member 14 a is inserted into the outwardly facing U-shapedchannel of the abutting edge of the adjacent second panel assembly (suchas assembly 12 b) to interconnect the panel assemblies. In a preferredembodiment of the system 10, spline members 14 are made from galvanizedsteel with a bonded rubber seal on the outside surface, which enables aweatherproof seal between adjacent panel assemblies 12 of the wallstructure, eliminating the necessity of additional weatherproofingmeasures such as surfacing, caulking, or cutting of expansion joints.Because such extra measures are not necessary, unlike prior artreferences, the only steps for wall construction with the panelattachment system 10 is mounting of the panel assemblies 12 andinterconnection via spline members 14. No additional sealing orfinishing steps are necessary. Further, the present invention allows thecreation of wall structures at times when temperatures will reachfreezing and below because a weatherproofing step is included with theinterconnection step through use of the spline member 14.

As FIGS. 5B-5E further illustrate, spline members 14 may have differentangles, curves or configurations in order to accommodate various walldesigns, including variations in angles and curves, or provide fordesired interconnections with molding pieces, detail assemblies, or anyother portion of the wall structure. For example, FIG. 5B illustrates aspline member 14 b for use at right angle, corner junctions. FIG. 5Cillustrates a spline member 14 c for use at T-junctions. FIG. 5Dillustrates a spline member 14 d for use at Y-junctions. FIG. 5Eillustrates a spline member 14 e for use at an angled junction. Thepossible structures of spline members that can be used in connectionwith the present invention are not exhausted by the designs illustratedin FIGS. 5A-5E.

FIGS. 6A-6D show various molding pieces or connection members 16 thatcan be used to finish edges of panel assemblies 12 (as a molding piece)or alternatively can be positioned between adjacent panel assemblies 12for structural support or merely to improve aesthetics of the wallstructure (as a connection member). As illustrated in FIG. 1, moldingpieces 16 are attached to adjacent portions of the wall structure viaspline members 14 inserted into generally outwardly facing U-shapedchannels 54 disposed in each molding piece 16. In a preferred embodimentof the present invention, molding pieces 16 a, in the general formillustrated in FIG. 6A, may be used as moldings around the edges of awindow or door in the wall structure. The molding piece 16 a is attachedto the edge of a panel assembly 12 in a manner similar to the manner inwhich adjacent panel assemblies 12 are attached to one another—i.e., viaa spline member 14 inserted into respectively facing U-shaped channels30 or 54 of each adjacent portion of the wall structure (be it a panelassembly or a molding piece). Molding pieces 16 b and 16 c, as shown inFIGS. 6B and 6C, act as connection members between two panel assemblies12, specifically being used in conjunction with basic flat splinemembers 14 a (as illustrated in FIG. 5A) to form inner or outer cornersof the wall structure. Molding piece 16 d is an alternate design to theedge molding piece design of FIG. 6A, specifically illustrated avariation is the detail that may be used for the molding piece. In apreferred embodiment, molding pieces 16 can be adapted to match thefinish, color, size, shape and general appearance of the panels 18 thatform the wall structure. For example, for exterior application of thepanel attachment system 10, the panel assemblies 12 and the moldingpieces 16 may be both manufactured from Styrofoam® coated withfiber-reinforced concrete painted to the desired design for the wall.

An advantage of the panel attachment system 10 of the present inventionis the ability to construct an essentially finished wall structure in aquick manner without the added time and labor for sealing adjacent wallpanels. Additionally, the present invention allows for simpleconstruction of a wall structure without exposed fasteners, such asscrews, as is commonly the case with prior art methods of paneling awall structure. In connection with this aspect of the invention, thepanel assemblies 12 and molding pieces 16 of the system 10 are designedfor quick mounting to a wall frame structure and quick interlocking toadjacent pieces of the panel attachment system 10, as described above,but without exposed hardware used for mounting or interlocking of thecomponents.

For example, FIGS. 7A-7C depict the interlocking connection oflongitudinally adjacent molding pieces, or connection members, in apreferred embodiment. Each molding piece 16 is equipped with at leastone track 56 defining the generally outwardly facing U-shaped channel 54into which a spline member 14 can be inserted to connect the moldingpiece 16 to another portion of wall structure, such as an adjacent panelassembly 12. A first longitudinal end 58 of each molding piece 16features an outwardly jutting piece of track 56 forming a “male”connection piece 60. In this embodiment, the “male” connection piece 60includes a screw hole 62 for connection to the inserted spline member14. As shown, for example, in FIG. 7A, a portion of the “male”connection piece 60 on the back side of the track 56 is cut away so thatthe connection piece 60 is not flush with the back side of the moldingpiece 16. A second opposite longitudinal end 64 of the molding piece 16features a recess forming a “female” connection piece 66 where the track56 and the material of the molding piece 16 have been cut away, leavinga tab 68 that slides behind the “male” connection piece 60 and locks themolding piece 16 behind a longitudinally adjacent molding piece, asshown in FIGS. 7B and 7C.

The structural design of the molding piece's respective longitudinalends 58 and 64 allows longitudinally adjacent molding pieces to beinterconnected by inserting the “male” connection piece 60 into theadjacent “female” connection piece 66 along an edge of a panel assembly12, all while concealing the respective tracks 56 and screws of eachmolding piece 16. The free ends of the first and last molding piece in arow are screwed or otherwise attached to the inserted spline member 14.Occasionally the screw hole will have to be caulked or otherwiseconcealed. FIGS. 7A and 7B illustrate the process of positioning the“female” connection piece 66 of a new molding piece onto the “male”connection end 60 of longitudinally adjacent molding piece that hasalready been positioned with respect to an overlapping spline member 14.The new molding piece is pivoted into position with respect to both theexisting molding piece and the spline member 14. Once the new moldingpiece is in the position shown in FIG. 7B, it can be slid along thespline member 14 into engagement with the existing molding piece so thatthe “male” connection piece 60 of the existing molding piece is receivedin the “female” connection piece 66 of the new molding piece. The tab 68associated with the “female” connection piece 66 aligns with theprojection of the “male” connection piece 60 to provide the channel 54at the junction to receive a spline member 14 so that both moldingpieces 16 are secured into place in the wall structure. FIG. 7C showsthe molding pieces interconnected after being positioned into the wallstructure.

To reduce time at a job site, panel assemblies such as 12 a and 12 b inFIG. 1 are preferably pre-made and shipped to the site prior tobeginning construction of a wall structure. As illustrated in FIGS. 8Aand 8B, each panel to be used in the bottom course of panel assembliesis fitted with additional screw tabs, generally designated by referencenumeral 70, along the bottom edge. Screw tabs 70 can later be concealedby molding pieces 16 interconnected to the bottom of applicable panelassemblies. The first panel assembly 12 mounted in place is positionedon the wall frame structure 46 on horizontal Z-bars 48 or the like usingmounting members 40 attached to the frame 20, as described above withrespect to FIG. 3. Once the first panel assembly 12 is properlypositioned on the wall frame structure, it is attached to the Z-bars 48,for example, with screws through holes 44 in the outer surface of hooks42, or by another means of attachment to the wall frame structure inaccordance with the knowledge of one skilled in the art. Appropriatelyshaped spline members 14 are then inserted into the outwardly facingU-shaped channels 30 along the perimeter of the mounted panel assembly12. Subsequent panel assemblies are positioned adjacent the mountedpanel assembly and interconnected by inserting spline members 14 intorespective facing U-shaped channels 30 of abutting sides of adjacentpanel assemblies so that the adjacent edges of the respective panels 18are essentially abutting, eliminating the need to treat the joints orseams. Following interconnection of abutting edges of adjacent panelassemblies, the panel assemblies are attached to the wall framestructure 46. As FIG. 8B illustrates, the offset hook arrangement usedon the respective frames 20 of the panel assemblies enables each panelassembly to be attached to adjacent panel assemblies 12 on all abuttingedges via spline members 14 inserted within respective facing U-shapedchannels 30 without the need for additional sealing, caulking, or otherconcealment of holes or seams.

Furthermore, connection members or molding pieces 16 with outwardlyfacing U-shaped channels 54, such as those illustrated in FIGS. 6A-6D,can be attached to panel assemblies 12 using the appropriately shapedspline member 14. Molding pieces 16 having a single U-shaped channel 54,such as those shown in FIGS. 6A and 6D, are generally positioned andattached to the edges of panel assemblies 12 on the end of a wallstructure or at a window or doorway via spline members 14 inserted intorespective U-shaped channels 30 and 54. Connection members 16 with atleast two outwardly facing U-shaped channels 54 positioned at agenerally 90° angle, such as that shown in FIGS. 6B and 6C, may be usedto form inner or outer corners of the wall structure. Differentembodiments of such connection members or molding pieces 16 arepossible, including members with various angles, curves and/or differentquantities of U-shaped channels 54, depending on the specifications forthe design of the wall structure.

When inserted into the outwardly facing U-shaped channels of abuttingedges of wall structure components, spline members 14 generally formweatherproof seals, alleviating the requirement of furtherweatherproofing steps such as cutting thermal expansion joints oradditional sealing treatments. The only necessary resurfacing measurerequired is an occasional filling of a single screw hole in the first orlast portion of wall structure, which generally will be a moldingcomponent. All other screws used in assembling and constructing the wallstructure are concealed by subsequently positioned panel assemblies,connection members, or molding pieces.

The foregoing description of embodiments of the invention has beenpresented for the purpose of illustration and description, it is notintended to be exhaustive or to limit the invention to the formdisclosed. Obvious modifications and variations are possible in light ofthe above disclosure. The embodiments described were chosen to bestillustrate the principals of the invention and practical applicationsthereof to enable one of ordinary skill in the art to utilize theinvention in various embodiments and with various modifications assuited to the particular use contemplated. It is intended that the scopeof the invention be defined by the claims appended hereto.

1. A panel attachment system for constructing a wall structure,comprising: at least one panel assembly comprising a panel having aperimeter, a front face and a rear face; and a frame attached to therear face of the panel and including a generally outwardly facingchannel disposed proximate the perimeter of the panel; and at least onespline member that is insertable into the channel of the frame tointerconnect the corresponding panel assembly to an adjacent portion ofthe wall structure.
 2. The panel attachment system according to claim 1,wherein the frame has a perimeter shape generally corresponding to theperimeter of the panel, and further wherein the channel is disposedabout the perimeter shape of the frame.
 3. The panel attachment systemaccording to claim 2, wherein the panel of said panel assembly has agenerally rectangular shape, said frame having a correspondingrectangular shape, and each side of said frame having a channel suchthat each said channel is disposed proximate a respective edge of therectangular perimeter of the panel.
 4. The panel attachment systemaccording to claim 1, wherein the frame comprises at least one trackdefining the channel, said at least one track being attached to the rearface of the panel proximate the perimeter of the panel.
 5. The panelattachment system according to claim 4, wherein the panel of said panelassembly has a generally rectangular shape, said frame having acorresponding rectangular shape defined by four tracks each having achannel such that each said channel is disposed proximate a respectiveedge of the rectangular perimeter of the panel.
 6. The panel attachmentsystem according to claim 1, wherein said at least one spline member isinsertable into the channel of the frame to form a seal at the jointbetween the panel assembly and the adjacent portion of the wallstructure to which it is interconnected.
 7. The panel attachment systemaccording to claim 1, wherein the frame further comprises a plurality offastening members for attaching the frame to the rear face of the panel.8. The panel attachment system according to claim 1, wherein the framefurther comprises at least one mounting member for mounting the panelassembly to a wall frame in a building structure.
 9. The panelattachment system according to claim 8, wherein the at least onemounting member comprises a hook.
 10. The panel attachment systemaccording to claim 1, comprising a plurality of panel assemblies thatmay be positioned adjacent one another to create the wall structure,each said panel assembly comprising a respective panel having aperimeter, a front face and a rear face, and a frame attached to therear face of the corresponding panel and having a perimeter shapegenerally corresponding to the perimeter of the panel to which it isattached, each said frame having a generally outwardly facing channeldisposed about the perimeter shape of the frame and positioned proximatethe perimeter of the corresponding panel such that the channels alongabutting edges of adjacent panel assemblies face one another; andwhereby the abutting edges of adjacent panel assemblies areinterconnected via a spline member placed within respective facingchannels of the adjacent panel assemblies.
 11. The panel attachmentsystem according to claim 10, further comprising a connection memberincluding at least one generally outwardly facing channel for receivinga spline member to interconnect said connection member with an adjacentpanel assembly.
 12. The panel attachment system according to claim 11,wherein said connection member is positionable between adjacent panelassemblies, said connection member having a generally outwardly facingchannel corresponding to each adjacent panel assembly such that eachchannel in the connection member faces the respective generallyoutwardly facing channel in the adjacent panel assembly, and wherebyeach panel assembly is interconnected to said at least one connectionmember via a spline member placed within respective facing channels ofthe panel assemblies and the connection member.
 13. The panel attachmentsystem according to claim 11, wherein said connection member is amolding positionable at the edge of a panel assembly.
 14. A panelattachment system for creating a wall structure, comprising: a pluralityof panel assemblies, each said panel assembly comprising a panel havinga perimeter, a front face and a rear face; and a frame attached to therear face of the panel and including a generally outwardly facingchannel disposed proximate the perimeter of the panel; wherein thechannels along abutting edges of adjacent panel assemblies face oneanother; and whereby adjacent panel assemblies are interconnected via aspline member placed within respective facing channels of the adjacentpanel assemblies.
 15. The panel attachment system according to claim 14,wherein the panel of each panel assembly has a respective perimetershape, and the frame attached to said panel has a perimeter shapegenerally corresponding to the perimeter of said panel, and furtherwherein the channel of said frame is disposed about the perimeter shapeof said frame.
 16. The panel attachment system according to claim 14,further comprising a connection member including at least one generallyoutwardly facing channel for receiving a spline member to interconnectsaid connection member with at least one adjacent panel assembly.
 17. Aframe for mounting a panel attached thereto to a wall frame, comprising:at least one frame member defining a perimeter of said frame generallycorresponding to the perimeter of the panel attached thereto; aplurality of fastening members for mounting the panel to the frame; anda generally outwardly facing channel disposed in the at least one framemember about the perimeter of the frame such that the channel ispositioned proximate the perimeter of the panel.
 18. The frame accordingto claim 17, wherein frame has a generally rectangular shape defined byfour frame members each having a channel.
 19. The frame according toclaim 17, wherein the frame further comprises at least one mountingmember for mounting the frame to the wall frame.
 20. The frame accordingto claim 17, wherein the channel is capable of receiving at least onespline member to interconnect the frame to an adjacent frame of likeconstruction so that respective panels mounted thereto are positionedadjacent one another to define a wall.